Table of Contents
Advertisement
Advertisement
Chapters
Table of Contents
Subscribe to Our Youtube Channel
Related Manuals for Doosan G625XW
Summary of Contents for Doosan G625XW
- Page 1 50 Hz: G625 - G690 - G750XW/XF 60 Hz: G655 - G750 - G800 - G850XW/XF OPERATION & MAINTENANCE MANUAL Original Instruction This manual contains important safety information and must be made available to personnel who operate and maintain this machine. 46689185_en_A_12/15...
-
Page 3: Table Of Contents
Generator Serial Number Engine Serial Number NOTES: YOUR DIPP DEALER: ADDRESS: PHONE: Doosan Benelux SA Drève Richelle 167 B-1410 Waterloo BELGIUM 50 Hz: G625 - G690 - G750XW/XF OPERATION & MAINTENANCE MANUAL 60 Hz: G655 - G750 - G800 - G850XW/XF... - Page 4 50 Hz: G625 - G690 - G750XW/XF OPERATION & MAINTENANCE MANUAL 60 Hz: G655 - G750 - G800 - G850XW/XF...
-
Page 5: Foreword
Operation within the ambient temperature range • © COPYRIGHT 2015 specified in the GENERAL INFORMATION section of DOOSAN COMPANY this manual. 50 Hz: G625 - G690 - G750XW/XF OPERATION & MAINTENANCE MANUAL 60 Hz: G655 - G750 - G800 - G850XW/XF... - Page 6 50 Hz: G625 - G690 - G750XW/XF OPERATION & MAINTENANCE MANUAL 60 Hz: G655 - G750 - G800 - G850XW/XF...
-
Page 7: General Data
GENERAL DATA CONTENTS GENERAL DATA ..............................ELECTRICAL DATA..............................50 Hz: G625 - G690 - G750XW/XF OPERATION & MAINTENANCE MANUAL 60 Hz: G655 - G750 - G800 - G850XW/XF... - Page 8 GENERAL DATA UNIT MODEL 50HZ G625XW/XF G690XW/XF G750XW/XF Engine Speed - RPM 1500 1500 1500 UNIT MODEL 60HZ G655XW/XF G750XW/XF G800XW/XF G850XW/XF Engine Speed - RPM 1800 1800 1800 1800 Engine Fuel Diesel Diesel Diesel Diesel Manufacturer Doosan Doosan Doosan...
-
Page 9: Safety
SAFETY CONTENTS SAFETY DECALS ..............................GRAPHIC FORM AND MEANING OF ISO SYMBOLS .................. SAFETY INSTRUCTIONS ............................ EARTHING ..............................IF USED AS ALTERNATE POWER SUPPLY ....................HAZARDOUS SUBSTANCE PRECAUTION ....................GENERAL INFORMATION ..........................Electricity Materials Battery Radiator Transport 50 Hz: G625 - G690 - G750XW/XF OPERATION &... -
Page 10: Safety Decals
SAFETY DECALS GRAPHIC FORM AND MEANING OF ISO SYMBOLS PROHIBITION / MANDATORY INFORMATION / INSTRUCTIONS WARNING WARNING: Electrical shock risk WARNING - Pressurised component WARNING - Hot surface. or system. WARNING - Pressure control. WARNING - Corrosion risk. WARNING - Air/gas flow or Air discharge. - Page 11 WARNING - Maintain correct tyre WARNING - Before connecting the tow WARNING - For operating temperature pressure. bar or commencing to tow consult the below 0° C (32° F), consult the Operation & Maintenance manual. Operation & Maintenance manual. WARNING - Do not undertake any WARNING - Consult the Operation &...
- Page 12 Lifting point. On (power). Off (power). Read the Operation & Maintenance When parking use prop stand, Compressor oil filling manual before operation or handbrake and wheel chocks. maintenance of this machine is undertaken. Diesel fuel Parking brake. Rough Service Designation. No open flame.
-
Page 13: Safety Instructions
SAFETY INSTRUCTIONS DANGER CAUTION This machine is not designed for operating life- Exercise extreme caution when using booster sustaining equipment. It is equipped with a safety battery. To jump battery, connect ends of one booster shutdown system that will cause the machine to stop cable to the positive (+) terminal of each battery. -
Page 14: Earthing
WARNING WARNING Failure to properly earth the Generator Set can result Electrical Shock - in severe injury or death. Do not operate electrical equipment while standing in IF USED AS ALTERNATE POWER SUPPLY water, on wet earth or with wet hands or shoes. Connect only after the main service entrance switch Use extreme caution when working on electrical has been DISCONNECTED and LOCKED OPEN. -
Page 15: Hazardous Substance Precaution
HAZARDOUS SUBSTANCE PRECAUTION GENERAL INFORMATION Ensure that the operator reads and understands the decals and consults the manuals before maintenance or CAUTION operation. Ensure that the Operation & Maintenance manual, and Use extreme care to avoid contacting hot surfaces the manual holder, are not removed permanently from (engine exhaust manifold and piping). - Page 16 Ensure that adequate ventilation of the cooling system and exhaust gases is maintained at all times. The following substances are used in the manufacture of this machine and may be hazardous to health if used incorrectly: • anti-freeze • engine lubricant •...
-
Page 17: Operating Instructions
OPERATING INSTRUCTIONS CONTENTS OPERATING INSTRUCTIONS ..........................COMMISSIONING ............................CONNECTING THE LOAD..........................PRIOR TO STARTING ............................ STARTING............................... STOPPING ..............................CONTROLLER ..............................QUICKSTART GUIDE ............................. STARTING THE ENGINE..........................STOPPING THE ENGINE ..........................STOP / RESET MODE ............................MANUAL MODE ..............................STARTING SEQUENCE..........................ENGINE RUNNING ............................ -
Page 18: Operating Instructions
OPERATING INSTRUCTIONS Never operate unit without first observing all safety PRIOR TO STARTING warnings and carefully reading the operation & Before starting the engine, carry out the following checks: maintenance manual shipped from the factory with this machine. 1. Engine oil level: Add as required. COMMISSIONING Upon receipt of the unit, and prior to putting it into CAUTION... -
Page 19: Starting
STARTING STOPPING 1. Turn off all external electrical power loads. CAUTION 2. Turn Main Breaker “OFF”. 3. Allow 5 minute cool down. Use the EMERGENCY STOP button ONLY in the event of an emergency. 4. Push controller “STOP” Button. NEVER use it for normal shut-down. 5. -
Page 20: Controller
CONTROLLER NOTE: The following descriptions detail the sequences followed by a module containing the standard ‘factory configuration’. Always refer to your configuration source for the exact sequences and timers observed by any particular module in the field. QUICKSTART GUIDE This section provides a quick start guide to the module’s operation. STARTING THE ENGINE Press the Manual Mode button . -
Page 21: Stopping The Engine
STOPPING THE ENGINE Select Stop/Reset mode. The generator is stopped NOTE: For further details, see the section entitled ‘OPERATING INSTRUCTIONS’ elsewhere in this manual. 50 Hz: G625 - G690 - G750XW/XF OPERATION & MAINTENANCE MANUAL 60 Hz: G655 - G750 - G800 - G850XW/XF... -
Page 22: Stop / Reset Mode
STOP / RESET MODE NOTE: If a digital input configured to panel lock is active, changing module modes is not possible. Viewing the instruments and event logs is NOT affected by panel lock. Stop/Reset Mode is activated by pressing the Stop/Reset Mode button. -
Page 23: Manual Mode
MANUAL MODE NOTE: If a digital input configured to panel lock is active, changing module modes is not possible. Viewing the instruments and event logs is NOT affected by panel lock. Manual Mode is activated by pressing the Manual Mode button. -
Page 24: Engine Running
ENGINE RUNNING Once the engine is running and all starting timers have expired, the animated Engine Running icon is displayed. In Manual Mode , the load is not transferred to the generator unless a ‘loading request’ is made. A loading request can come from a number of sources. •... -
Page 25: Test Mode
TEST MODE NOTE: If a digital input configured to panel lock is active, changing module modes is not possible. Viewing the instruments and event logs is NOT affected by panel lock. Test Mode is activated by pressing the Test Mode button. -
Page 26: Engine Running
ENGINE RUNNING Once the engine is running and all starting timers have expired, the animated Engine Running icon is displayed. In Test Mode , the load is automatically transferred to the generator. NOTE: The load transfer signal remains inactive until the Oil Pressure has risen. This prevents excessive wear on the engine. -
Page 27: Automatic Mode
AUTOMATIC MODE NOTE: If a digital input configured to external panel lock is active, changing module modes is not possible. Viewing the instruments and event logs is NOT affected by panel lock. Auto Mode is activated by pressing the Auto Mode button. -
Page 28: Engine Running
ENGINE RUNNING Once the engine is running and all starting timers have expired, the animated Engine Running icon is displayed. The generator is placed on load if configured to do so. NOTE: The load transfer signal remains inactive until the Oil Pressure has risen. This prevents excessive wear on the engine. -
Page 29: Engine Operation And Maintenance
ENGINE OPERATION AND MAINTENANCE CONTENTS PERFORMANCE AND SPECIFICATIONS ......................31 TECHNICAL INFORMATION ..........................35 ENGINE MODEL AND SERIAL NUMBER .......................35 REGULAR INSPECTION - DP180 AND DP222 ENGINES..................36 GENERAL INFORMATION..........................36 ROUTINE INSPECTION...........................36 REGULAR INSPECTION TABLE ...........................37 GENERAL CONDITIONS ..........................37 USE OF GENUINE PARTS ............................38 COOLING SYSTEM..............................39 GENERAL INFORMATION..........................39 COOLANT STANDARDS ..........................39... - Page 30 CLEANING OF THE AIR FILTER ELEMENT....................55 CHANGING THE AIR FILTER ELEMENT......................56 TURBOCHARGER ............................56 ROUTINE CHECK AND SERVING THE TURBOCHARGER ................56 DISASSEMBLY AND CLEANING A TURBOCHARGER .................56 CYLINDER BLOCK/HEAD .............................57 VALVE CLEARANCE ............................57 ADJUSTING THE VALVE CLEARANCE......................57 TIGHTENING CYLINDER HEAD BOLT ......................58 CYLINDER COMPRESSION PRESSURE.......................59 ELECTRIC SYSTEM ..............................60 BATTERY .................................60...
-
Page 31: Performance And Specifications
PERFORMANCE AND SPECIFICATIONS DP180L Item Remarks DP180LBS DP180LBF DP180LAS DP180LAF General Information Water-cooled, 4cycle, V-type, Turbo charger & inter cooled Engine types (air to air) Cylinder liner type Wet type liner No. of cylinder - bore x stroke 10 - 128 X 142 (mm) Total displacement (cc) 18,273... - Page 32 DP180L Item Remarks DP180LBS DP180LBF DP180LAS DP180LAF Lubrication System Lubrication method Fully forced pressure feed type Type Gear type Oil pump Driving type Driven by crankshaft gear Oil filter Full flow, Cartridge type Max. Oil capacity (litres) Min. Idle speed Min.
- Page 33 DP222L Item Remarks DP222LAS DP222LBS DP222LBF DP222LCS DP222LCF General Information Water-cooled, 4cycle, V-type, Turbo charger & inter cooled Engine types (air to air) Cylinder liner type Wet type liner No. of cylinder - bore x stroke 12 - 128 X 142 (mm) Total displacement (cc) 21,927...
- Page 34 DP222L Item Remarks DP222LAS DP222LBS DP222LBF DP222LCS DP222LCF Lubrication System Lubrication method Fully forced pressure feed type Type Gear type Oil pump Driving type Driven by crankshaft gear Oil filter Full flow, Cartridge type Max. Oil capacity (litres) Min. Idle speed Min.
-
Page 35: Technical Information
TECHNICAL INFORMATION ENGINE MODEL AND SERIAL NUMBER • The engine model and serial number are located on the engine as illustrated. • These numbers are required when requesting warranty and ordering parts. EI6OM011 EI6OM012 Engine serial No. (example 1 : DE12T) Serial No. -
Page 36: Regular Inspection - Dp180 And Dp222 Engines
REGULAR INSPECTION - (DP180 AND DP222 ENGINES) CAUTION GENERAL INFORMATION Incorrect inspection methods may cause engine After purchasing an engine, over time, each of the faults. engine’s parts will age and the initial engine performance cannot be maintained. Cleaning an engine with liquids such as water or wax Regular inspection and replacement of components may cause breakdown of electrical parts. -
Page 37: Regular Inspection Table
REGULAR INSPECTION TABLE GENERAL CONDITIONS Regular inspection and replacement according to the recommended regular inspection table allows the engine to be maintained with optimum conditions and best performance for a long period and prevent unexpected accidents in advance. ( o :Inspection and Adjustment, • : Replacement ) Inspection interval (Hours) Check Points Daily... -
Page 38: Use Of Genuine Parts
Using unauthorized or remanufactured parts may cause critical damage and faults to engine for which Doosan shall not be held liable. 50 Hz: G625 - G690 - G750XW/XF OPERATION & MAINTENANCE MANUAL 60 Hz: G655 - G750 - G800 - G850XW/XF... -
Page 39: Cooling System
COOLING SYSTEM CAPACITY OF COOLANT GENERAL INFORMATION Coolant capacity (litres) Engine Mode Inside engine With radiator The coolant should be replaced according to the cycle specified in the inspection interval table. If the coolant About 91 gets dirty, the engine is overheated, and the coolant (Air on 43°C) overflows in the thermal expansion tank. -
Page 40: Measurement Of Coolant Concentration
MEASUREMENT OF COOLANT CONCENTRATION 5. Compare and confirm the parts with identical colours on the test sheet and the standard colour table. • Special Tools Figure Product Number/Name % GLYCOL / FREEZEPOINT (°C)(End Pad) 60.99901-0038 CC2602M test sheet SCA Units per litre Coolant test sheet TEST The coolant concentration can be measured as follows:... -
Page 41: Charging The Coolant
DISCHARGING THE COOLANT 4. Disassemble the coolant drain plug of the cylinder block, and drain it to a container. The coolant can be drained as follows: 1. Ensure that the engine and radiator are cooled. 2. Open the radiator cap. DANGER Never open the radiator cap while the engine is overheated. -
Page 42: Cleaning The Cooling Circuit
3. Pour in the coolant slowly. CLEANING THE COOLING CIRCUIT If the internal coolant circuit is contaminated by corrosion or foreign substances, the cooling effect is reduced. The CAUTION resistance in the coolant circuit may damage the mechanical seal of the coolant pump. The reduced performance in the cooling circuit may be Be careful not to let foreign substances flow into the caused by use of incorrect type or quantity of antifreeze... -
Page 43: Inter Cooler
INTER COOLER The air cooler adopts an air cooling fan, which has sufficient cooling capacity. The life and performance of an air cooler greatly depends on the intake air conditions. Dirty air may contaminate and clog the cooling pins. This results in reduced engine power or engine failure. -
Page 44: Lubrication System
API CD or above SAE 15W40 API CD or above DP 222L NOTE: Use of Doosan genuine engine oil is recommended. 50 Hz: G625 - G690 - G750XW/XF OPERATION & MAINTENANCE MANUAL 60 Hz: G655 - G750 - G800 - G850XW/XF... -
Page 45: Engine Oil Capacity
ENGINE OIL CAPACITY 3. Insert the oil level gauge, and then remove it to check the engine oil level, viscosity, and contamination. Replenish the engine oil based on the following Replenish or replace the engine oil if required. recommended oil amount. Engine oil capacity (litres) Engine Model Max. -
Page 46: Replacement Of Engine Oil
When replacing the oil filter cartridge, be sure to use the genuine Doosan part. 7. Stop the engine and wait for approximately 10 minutes. Check the oil level and fill the oil if required. -
Page 47: Fuel System
The quality of fuel is very important to satisfy the engine GENERAL INFORMATION performance, extension of engine life and the allowable exhaust gas level. Doosan engines are designed to use The fuel injection pump and nozzle are composed of very diesel fuel available in the local market. If the optimum sophisticated components with high precision. -
Page 48: Water Draining From Fuel Filter
WATER DRAINING FROM FUEL FILTER REPLACING FUEL FILTER An oil filter has two functions: oil filtering and water separation. 1. The water separation function of the fuel filter drains water and sediment from the water separator. 2. Stop the engine, and loosen the drain plug for water separation manually. -
Page 49: Preventing Fuel Contamination
9. Tighten it by 3/4 to 1 turn with a fuel filter wrench. CAUTION If any parts that contain a seal ring (copper seal ring, rubber coating seal ring, etc.) are disassembled, then replace the seal ring with a new one. Failure to do so may cause leakage in the fuel filter connections preventing normal functioning. -
Page 50: Injector Maintenance
3. Operate the priming pump until the air is discharged completely. DANGER Fuel is highly inflammable. Fire may occur if there are naked flames or sparks near the engine when air bleeding in the fuel circuit from the priming pump. CAUTION DV2213022A If any parts that contain a seal ring (copper seal ring,... -
Page 51: Removal Of Nozzle
CAUTION As the injection nozzle is designed to operate under high pressure, it should be handled with care. Always keep hands away from the fuel jet, as there is a risk of injury. Do not inhale the atomized fuel oil. If possible, work under an extraction system. -
Page 52: Installation Nozzle
INSTALLATION NOZZLE project only slightly from the collet and drive out the carbon by lightly tapping on the tool. 1. Clean seat in cylinder head. • Before reassembly thoroughly wash nozzle body and 2. Insert nozzle holder with new gasket. needle in clean test oil. -
Page 53: Adjusting Injection Timing
3. To check the injection timing degree, ensure the ADJUSTING INJECTION TIMING V-type edge of the flywheel housing sight hole If upper pre-checked injection timing degree is wrong, coincides with the engine injection timing degree follow the procedure below. marked on the flywheel corresponding to the fuel delivery position. -
Page 54: Intake/Exhaust System
INTAKE/EXHAUST SYSTEM DISASSEMBLY OF AIR FILTER GENERAL INFORMATION The air filter purifies dust and foreign substances DANGER included in the air and supplies clean air into the engine. The air filter is directly related to engine lifetime, emissions, and engine output. Periodically check, clean, Allowed only when the engine is stopped. -
Page 55: Cleaning Of The Air Filter Element
CLEANING OF THE AIR FILTER ELEMENT 1) Before washing the element, clean the element by using compressed air as described above. Clean the air filter element by using the most suitable method for the work environment among the three 2) Soak the element in the warm cleaning solvent for methods stated below. -
Page 56: Changing The Air Filter Element
CHANGING THE AIR FILTER ELEMENT ROUTINE CHECK AND SERVING THE TURBOCHARGER 1. Remove the hex nut, remove the dirty element. The turbocharger performance is affected by the maintenance state of the engine. Regularly perform inspection and maintenance as specified in order to maintain turbocharger performance. -
Page 57: Cylinder Block/Head
CYLINDER BLOCK/HEAD • 12 Cylinder engine VALVE CLEARANCE Adjust the valve clearance. • When disassembling the engine or cylinder head. • When there is excessive noise in the valve connection. • When the engine runs abnormally even if the fuel injection system is normal. -
Page 58: Tightening Cylinder Head Bolt
TIGHTENING CYLINDER HEAD BOLT Engine Model In. valve Ex. valve 1. Retightening cylinder head bolt on new engine. DP180LBS 0.25mm 0.35mm DP180LBF 0.25mm 0.35mm Intake side injector DP180L DP180LAS 0.25mm 0.35mm DP180LAF 0.25mm 0.35mm DP222LAS 0.25mm 0.35mm DP222LBS 0.25mm 0.35mm DP222L DP222LBF 0.25mm... -
Page 59: Cylinder Compression Pressure
2. Tightening cylinder head bolts after a repair. (Engine cold). CAUTION Intake side injector The two outside screws (intake and exhaust side) must not be retightened. loosen cylinder head bolts before re-tightening. Tighten them by turning by a further 90° (1/4 revolution) from their actual position. When a cylinder head has been removed the cylinder head gasket must always be changed. -
Page 60: Electric System
ELECTRICAL SYSTEM BATTERY • Check the battery for cracks and ensure there is no electrolyte leakage. Replace the battery if defective. • Check the amount of electrolyte, and replenish distilled water if insufficient. • Check the specific gravity of electrolyte. If it is below the specified value (1.12 ~ 1.28), replenish it. -
Page 61: Others/Driving System
OTHERS/DRIVING SYSTEM 2) Apply tester to belt at a point midway between two pulleys so that edge of contact surface (2) is flush with the V-belt. V-BELT The tension of the V-belts should be checked daily. 1. Change the V-belts if necessary. 1) If wear or differing tensions are found in a multiple V-belt drive, always replace the complete set of V-belts. - Page 62 5. Tension adjustment and V-belt replacement. DV2213050B 1) Loosen the fixing bolt (1). 2) Loosen the lock nut (2). 3) Adjust the bolt (3) until belt have correct tension. 4) Tighten the fixing bolt (1) and nut (2). 5) To replace the V-belt, loosen the fixing bolts (1) and the lock nut (2) and push the tension pulley inwards by turning the adjusting bolt (3) counter clockwise.
-
Page 63: Alternator Installation & Maintenance
ALTERNATOR INSTALLATION AND MAINTENANCE CONTENTS LSA 49.1 - 4 POLES ALTERNATORS........................SAFETY MEASURES ............................WARNING SYMBOLS ............................RECEIPT ................................STANDARDS AND SAFETY MEASURES ......................INSPECTION ..............................IDENTIFICATION ............................STORAGE ............................... APPLICATIONS............................... CONTRAINDICATIONS TO USE ........................TECHNICAL CHARACTERISTICS........................ELECTRICAL CHARACTERISTICS........................ MECHANICAL CHARACTERISTICS ......................INSTALLATION .............................. -
Page 64: Lsa 49.1 - 4 Poles Alternators
LSA 49.1 - 4 POLES ALTERNATORS This manual concerns the alternator which you have just purchased. We wish to draw your attention to the contents of this maintenance manual. SAFETY MEASURES a) During operation, do not allow anyone to stand in front of the air outlet guards, in case anything is ejected from them. -
Page 65: Receipt
RECEIPT STORAGE Prior to commissioning, machines should be stored: STANDARDS AND SAFETY MEASURES - away from humidity (< 90%); after a long period of storage, check the machine insulation. To prevent the Our alternators comply with most international standards. bearings from becoming marked, do not store in an environment with significant vibration. -
Page 66: Technical Characteristics
TECHNICAL CHARACTERISTICS MECHANICAL CHARACTERISTICS • - Steel frame ELECTRICAL CHARACTERISTICS - Cast iron end shields - Greasable ball bearings PARTNER LSA 49.1 alternator is a machine without - Mounting arrangements: sliprings or revolving field brushes, wound as “2/3 pitch”; IM 1201 (MD 35) foot and flange mounted, single- 6 or 12-wire, with class H insulation and a field excitation bearing with SAE coupling disc. -
Page 67: Installation
INSTALLATION CAUTION Personnel undertaking various operations indicated in this section must wear personal protective equipment appropriate for mechanical and When coupling the alternator to the prime mover, do electrical hazards. not use the fan to turn the alternator or rotor. ASSEMBLY The holes of the coupling discs should be aligned with the flywheel holes by cranking the engine. -
Page 68: Terminal Connection Diagrams
CAUTION Ensure that the alternator has the degree of protection matching the defined environmental conditions. Mechanical checks Before starting the machine for the first time, check that: - all fixing bolts and screws are tight, - the cooling air is drawn in freely, - the protective grilles and housing are correctly in place, - the standard direction of rotation is clockwise as seen from the shaft end (phase rotation in order 1 - 2 - 3). - Page 69 Connection codes Voltage L.L Factory connection 12 wires Winding 50 Hz 60 Hz 190 - 208 190 - 240 208 - 220 190 - 208 R 450 voltage detection : 0 => (T3) / 220 V => (T2) Winding 50 Hz 60 Hz 380 - 415 380 - 480...
- Page 70 Connection codes Voltage L.L Factory connection 6 wires Winding 50 Hz 60 Hz 380 - 415 380 - 480 415 - 440 380 - 416 R 450 voltage detection : 0 => (T3) / 380 V => (T2) Winding 9 : R 450 voltage detection + transformer (See specific diagram 500 - 525 AREP or PMG)
- Page 71 Option connection diagram R791T interference suppression kit Remote voltage potentiometer (standard for CE marking) Connections Black Voltage adjustment via Black remote potentiometer Black Blue White Connection of the optional current transformer A / D connection D connection In/2 (D conn.) In/4 (D conn.) 12-wire 6-wire...
-
Page 72: Commissioning
Connection checks COMMISSIONING WARNING WARNING The machine can only be started up and used if the Electrical installations must comply with the current installation is in accordance with the regulations and legislation in force in the country of use. instructions defined in this manual. Check that: The machine is tested and set up at the factory. -
Page 73: Servicing - Maintenance
SERVICING - MAINTENANCE CAUTION SAFETY MEASURES Servicing or troubleshooting must be carried out strictly in Do not use: trichlorethylene, perchlorethylene, accordance with instructions so as to avoid the risk of trichloroethane or any alkaline products. accidents and to maintain the machine in its original state. -
Page 74: Mechanical Defects
It is imperative to lubricate the alternator during operation and on first use. Before using another grease, check for compatibility with the original one. MECHANICAL DEFECTS Fault Action Excessive overheating of one or - If the bearing has turned blue or if the grease has turned black, both bearings (bearing temperature change the bearing. - Page 75 Voltage too Adjust AVR voltage - Faulty AVR. Adjustment ineffective. high. potentiometer. - 1 faulty diode - Check the speed: possibility of cyclic irregularity. Voltage Adjust the AVR stability If no effect: try normal or fast - Loose connections. oscillations. potentiometer.
- Page 76 Checking the winding Assembly A: Connect a 12 V battery in series with a rheostat of You can check the winding insulation by performing a approximately 50 ohms - 300 W and a diode on both high voltage test. In this case, you must disconnect all exciter field wires (5+) and (6-).
-
Page 77: Dismantling, Reassembly
DISMANTLING, REASSEMBLY Replacing the NDE bearing on alternators connected to a diesel engine - Remove the lid of the protective cover (48) and the AVR CAUTION inspection door (466). - Disconnect the AVR. - Take off the panels (367 and 368) and the grilles (254 During the warranty period, this operation should and 255). - Page 78 - Replace the connection plate assembly (281 + 270). - Replace the connector link assembly (281 + 279). CAUTION - Replace the neutral link (278). - Connect the stator connections (T1 to T12) and the sensing wires. Replace the dismantled bearing with a new one. - Refit the panels (367) and 368) and the grilles 254 and 255).
-
Page 79: Installation & Maintenance Of The Pmg
Resistances of main windings at 20° C Average values for 6 winding - (12 wires) Stator After operational testing, replace all access panels or LSA 49.1 Rotor Field Armature covers. 0,0044 0,38 0,08 Dismantling and reassembly of the filters 0,0023 0,43 0,08 - Remove the grille (417) then take out the filter (418), as... -
Page 80: Spare Parts
SPARE PARTS FIRST MAINTENANCE PARTS Emergency repair kits are available as an option. After operational testing, it is essential to replace all They contain the following items: access panels or covers. Emergency kit AREP ALT 491 KS 001 ACCESSORIES AVR R 450 Space heater for use when stopped Diode bridge assembly The space heater must run as soon as the alternator... -
Page 81: Exploded Views, Parts List And Tightening Torque
EXPLODED VIEW, PARTS LIST AND TIGHTENING TORQUE LSA 49.1 SINGLE-BEARING 50 Hz: G625 - G690 - G750XW/XF OPERATION & MAINTENANCE MANUAL 60 Hz: G655 - G750 - G800 - G850XW/XF... - Page 82 LSA 49.1 SINGLE-BEARING Ref. Qty Description Screw Torque Ø Ref. Description Screw Torque AVR support stirrup Ø Stator assembly Right air intake guard Rotor assembly Left air intake guard Turbine DE cross-member Balancing disc NDE cross-member Lifting ring Connection plate Shaft extension key 3 or 4 Copper bar support Earth terminal...
-
Page 83: Main Breaker Operation
MAIN BREAKER OPERATION CONTENTS GENERAL ................................TYPES AND DESCRIPTIONS......................... PARTS AND FUNCTIONS ..........................OPERATION ................................CHARGING AND OPENING OPERATION ..................... CHARGING OPERATION ......................... Manual charging ..........................Motor charging............................. CLOSING OPERATION ..........................Manual closing............................. Electrical closing ..........................OPENING OPERATION ..........................Manual opening ........................... Electrical opening .......................... -
Page 84: General
GENERAL TYPES AND DESCRIPTIONS TemPower2 is available in types shown in Tables 3 and 4. Table 3 Standard types Frame size (A) 1250 1600 2000 2500 3200 4000 4000 Type AR208S AR212S AR216S AR220S AR325S AR332S AR440SB AR440S IEC, EN, AS Max. - Page 85 Table 3 Standard types (Cont’d) Frame size (A) 1250 1600 2000 2500 3200 4000 4000 Type AR208S AR212S AR216S AR220S AR325S AR332S AR440SB AR440S Vertical Vertical Line side Vertical, horizontal or front terminals terminals terminals Connection method Vertical Vertical Load side Vertical, horizontal or front terminals terminals terminals...
- Page 86 Table 6 shows the dielectric withstand voltage and the insulation resistance of the ACBs. CAUTION perform dielectric withstand/insulation resistance tests under other conditions than specified. Doing so may cause a malfunction. Table 6 Dielectric withstand voltage and insulation resistance Insulation Impulse resistance withstand...
- Page 87 Table 8 shows applicable current of the ACBs. The applicable current varies depending on the ambient temperatures. Table 8 Dependence of applicable current on ambient temperature AR208S AR212S AR216S AR220S AR325S AR332S AR440SB AR440S Type and conductor size 2×50×5t 2×80×5t 2×100×5t 3×100×5t 2×100x10t 3×100×10t 4×150×10t...
-
Page 88: Parts And Functions
PARTS AND FUNCTIONS Fig. 14 provides a general views of the ACB. ON-OFF indicator Front cover Charge indicator ON-OFF cycle counter OFF button Charging handle ON-OFF button cover Lock-in-OFF plate ON button ON-OFF button cover Overcurrent release (OCR) OCR cover Rating nameplate Position indicator Position padlock lever... - Page 89 Consists of breaker body (3) and draw-out cradle (2). Draw-out cradle Comes with main circuit terminals (48), control circuit terminals (38), auxiliary switches (41), and position switches (37). Breaker body Contains the ON-OFF mechanism, the closing coil,the tripping device, and overcurrent release (19).
- Page 90 Draw-out rail Use to draw out the breaker body from the draw-out cradle. Draw-out rail end Refer to “Operation Precautions”. Hook pin Refer to “Operation Precautions”. Body stopper Prevents the breaker body from falling when the body is drawn out from the draw-out cradle.
- Page 91 Main circuit terminals Allow connections of external conductors. These terminals are available in three configurations as shown in Fig. 16. Vertical terminals Horizontal terminals Front terminals Fig. 16 Main circuit terminals Lifting hole (ø20mm) Allows lifting attachments or wire ropes to be used for lifting the ACB. Protrusion Refer to “Operation Precautions”.
-
Page 92: Operation
OPERATION Do not bring your hand or face close to arc gas vent of the arc chamber while the ACB is energized. Otherwise, a burn may result from high-temperature CHARGING AND OPENING OPERATION arc gas blowing out of the arc gas vent when the ACB trips open. -
Page 93: Motor Charging
• Motor charging The control power of the overcurrent release (OCR) must be supplied before closing operation in order that the When the charge indicator (Fig. 23 (1) ) changes to internal program can be started. If the OCR trips open “DISCHARGED”... -
Page 94: Motion Of Operation Mechanisms
• Motion of operation mechanisms Figs. 24 - 27 illustrate the motion of the charging and ON- OFF mechanisms. Fig. 24 Closing motion 1 (discharge motion) Fig. 25 Closing motion 2 For manual closing operation, ON button (1) rotates Closing cam (8) rotating clockwise causes closing link counterclockwise. - Page 95 Fig. 26 Charging motion Fig. 27 Opening motion The charging handle or the charging motor provides a For manual opening operation, OFF button (1) rotates counterclockwise rotation to charging cam (1). This counterclockwise and trip linkage (2) rotates clockwise. rotates closing release lever (2) and closing tripper lever For electrical opening operation, push rod (1) protrudes (3) counterclockwise and a semicircular pawl engages downward from the shunt trip device (SHT) or the...
-
Page 96: Draw-Out And Insertion Operation
DRAW-OUT AND INSERTION OPERATION GENERAL The draw-out type ACB consists of the breaker body and the draw-out cradle. The main and control circuit terminals are installed on the draw-out cradle, which permits you to draw out and inspect or service the breaker body without the need for removing wiring from the terminals. -
Page 97: Draw-Out Operation
DRAW-OUT OPERATION Use the separate draw-out handle to draw-out the breaker body. • Moving the breaker body from the CONN. position to the TEST position 1. Open the ACB. (If the ACB remains closed, the draw- out handle (Fig. 29 (1) ) cannot be inserted). Never touch live terminal parts. -
Page 98: Moving The Breaker Body From The Test Position To The Isolated Position
• Moving the breaker body from the TEST position to PUTTING THE BREAKER BODY BACK INTO THE DRAW-OUT CRADLE the ISOLATED position 1. Open the ACB. (If the ACB remains closed, the draw- out handle (Fig. 29 (1) ) cannot be inserted). 2. -
Page 99: Moving The Breaker Body From The Isolated Position To The Test Position
• Do not leave the ACB body on the draw-out rail pulled out handle (Fig. 29 (1) ) cannot be inserted). out. 2. Unlock the position lock lever (Fig. 29 (14) ) if locked. 4. Make sure the breaker fixing bolts (Fig. 29 (2) ), if fitted, are loosened and not arrest the breaker body. -
Page 100: Contact Status Of Auxiliary And Position Switches
CONTACT STATUS OF AUXILIARY AND POSITION SWITCHES Tables 18 and 19 show the contact status of auxiliary switches and position switches respectively. Table 18-1 Contact status of auxiliary switches ACB state ACB state Status of Status of Breaker body position a-contact b-contact CONN. -
Page 101: On-Off Button Cover Locking Procedure
ON-OFF BUTTON COVER LOCKING PROCEDURE Lock the button cover using a padlock with ø6 shackle (up to 3 padlocks can be used) as shown in Fig. 32. The ON-OFF button cover is locked and the ON and OFF buttons cannot be operated. ON-OFF button cover ON-OFF button cover ON button... -
Page 102: Position Lock Lever Locking Procedure
POSITION LOCK LEVER LOCKING PROCEDURE 1. Move the breaker body to the desired position (CONN, TEST or ISOLATED). 2. Pull out the position lock lever shown in Fig. 34. 3. Lock the position padlock lever using a padlock with ø6 shackle (up to 3 padlocks can be used) as shown in Fig. 34. This prevents the draw-out handle from being inserted into the draw-out handle insertion hole, i.e., the breaker position cannot be changed. -
Page 103: Ocr Cover Locking Procedure
OCR COVER LOCKING PROCEDURE Lock the OCR cover using a padlock with ø6 shackle as shown in Fig. 36. The OCR cover cannot be opened, which prevents OCR settings from being changed. OCR cover Padlock OCR cover padlock hole Fig. 36 Padlocking the OCR cover 50 Hz: G625 - G690 - G750XW/XF OPERATION &... - Page 104 WIRING DIAGRAMS 50 Hz: G625 - G690 - G750XW/XF OPERATION & MAINTENANCE MANUAL 60 Hz: G655 - G750 - G800 - G850XW/XF...
-
Page 105: Warranty Conditions
/ owner that each STATUTORY OR OTHERWISE (EXCEPT THAT OF new Doosan Global Export Generator will be free from TITLE) INCLUDING ALL IMPLIED WARRANTIES AND defects in material and workmanship for twelve (12)
Need help?
Do you have a question about the G625XW and is the answer not in the manual?
Questions and answers